Pre-fabricated outdoor column

ABSTRACT

A pre-fabricated outdoor column assembly with an outer wall having the appearance of masonry. The pre-fabricated column assembly includes a tubular member with an insert disposed inside the tubular member. The insert has an opening for receiving a mounting post and is disposed in spaced apart relation to the ends of the tubular member such that a first space between the insert and the tubular member and a second space between the insert and the tubular member are formed.

CROSS-REFERENCE TO RELATED APPLICATION

The present application claims priority to U.S. Provisional PatentApplication No. 60/592,083 filed on Jul. 28, 2004, entitled“Pre-fabricated Outdoor Column,” which is incorporated herein byreference.

FIELD OF INVENTION

The present invention relates to outdoor columns for use asfree-standing landscape pillars, fencing columns, mailbox supportcolumns and commercial sign support columns.

BACKGROUND OF THE INVENTION

Outdoor columns are typically constructed with masonry buildingmaterials such as concrete, cement mortar, reinforcing steel bar, clay,marble, brick, stone or stackable pre-cast concrete block of variousshapes to achieve a column. Many of these materials are susceptible tocracking, scaling, effluorescence and hydro-freeze expansion. Also,these materials typically require a large foundation to support theweight of the building materials (typically 300-400 lbs.). Thesematerials require extensive labor, packaging and heavy equipment totransport from suppliers to the installation site. Accordingly, there isa need for an outdoor column that provides a durable, decorative,versatile, relatively inexpensive, and easy to install design for use inexterior landscape, fencing and sign support applications.

SUMMARY OF THE INVENTION

The present invention meets the above-described need by providing amulti-purpose, outdoor engineered column system that is prefabricatedfor rapid installation in the field.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention is illustrated in the drawings in which like referencecharacters designate the same or similar parts throughout the figures ofwhich:

FIG. 1 is a perspective view of the core of the present invention;

FIG. 2 is a top perspective view of the core of the present invention;

FIG. 3 is a perspective view of a column of the present invention shownin a mailbox application;

FIG. 4 is a perspective view of a column of the present invention shownin a commercial sign application;

FIG. 5 is a perspective view of a column of the present invention with alight kit installed;

FIG. 6 is a perspective view of a column of the present invention havinga simulated brick surface; and,

FIG. 7 is a perspective view of a mounting post attached to a concretepad.

DETAILED DESCRIPTION

Referring to FIG. 1, a core 10 is typically rectangular with four sidewalls 12, 14, 16, and 18 joined at the corners to form a hollowstructure with an inside cavity 19. The four walls 12, 14, 16, 18 may bejoined at ninety degree keyed corners and bonded together bycommercially available adhesives or the like as will be evident to thoseof ordinary skill in the art. The walls 12, 14, 16, and 18 may be moldedfrom suitable plastic materials such as polystyrene, polyethylene, orpolyurethane resins. The molding processes include, but are not limitedto, injection molding and rotocasting (rotational molding). Moldingprovides for speed of manufacture, however, other methods of forming thewalls may also be suitable. The outside surfaces 21 of the walls 12, 14,16, and 18 are provided with surfaces textures that resemble traditionalbrick, paneled stucco, natural stone or the like. The outside surfaces21 are provided with an exterior hard shell coating to provide theappropriate colors for the particular design and to provide a coating toprovide protection for use in outdoor environments. By way of exampleonly, the exterior coatings for the walls 12, 14, 16, 18 are acombination of commercially available polyurea base coating, acrylicbonding primer and an exterior insulation finishing system (EIFS)textured finish coating. The EIFS coating is a textured 100% acrylicpolymer finish coat used in both residential and commercialconstruction. As an alternative, the walls and surface texture for someof the columns such as stone-type may be formed integrally in arotocasting process where the textures and coloring would be inherent inthe polyethylene or polyurethane resin compound.

In the example shown, the top 20 and bottom 22 are square-shaped andopen. The inside cavity 19 is provided with an insert 24. The insert 24may be rectangular shaped with outside dimensions matching the insidedimension of the cavity 19 such that the insert 24 may be disposedsnugly inside the cavity 19. The insert 24 may be attached inside thecavity 19 by adhesives or the like as will be evident to those ofordinary skill in the art. The insert 24 has an opening 26 disposedalong a central longitudinal axis. The opening 26 is sized to receive astandard 4″×4″ post. The opening 26 is also provided with at least oneconduit raceway 28 defined along the edge of the opening 26 such thatconduit(not shown) can be run along the outside of the post inside theinsert 24. The electrical conduit/wire passageways or raceways 28 aredesigned to allow for electrical conduit or underground rated wire to beinstalled within the column 39 (FIG. 3) for supplying electrical powerto an optional light fixture kit 40 (FIG. 3), electrical outlet kit, orilluminated house number kit.

As shown in FIG. 1, the insert 24 is spaced apart from the bottom 22 ofthe side walls 12, 14, 16, 18 such that a space 30 is formed below theinsert 24. The space 30 provides for a degree of flexibility with.regard to the position of the conduit for applications such as lights orthe like.

The core 10 is also provided with a space 33 extending to the top 20.The space 33 provides an area for a mailbox 31 (FIG. 3) to be insertedinto the core 10 of the finished column 39 as shown in FIG. 3.

Turning to FIG. 2, wall 18 may be provided with an opening 36 in theshape of a mailbox. The opening 36 receives the mailbox 31 and newspaperbox (not shown) which is disposed above the post when the column isinstalled. The conduit raceways 28 may be disposed on different sides ofthe opening 26 such that the conduit is not obstructed by the mailbox31.

The structure described above for the core 10 provides the end user withthe ability to rapidly install the finished product over a commonlyavailable 4″×4″ wood, PVC, steel or aluminum post installed in theground. The post may be initially installed into an 8″-10″ hole that isaugured in the ground. The post is inserted into the hole to theappropriate depth depending on the local building codes with regard tothe frost line. The post is secured by backfilling with commonlyavailable pre-mixed concrete. The prefabricated column 39 is thenmounted over the installed post and bonded to the post usingcommercially available exterior rated adhesives or the like. Using a4″×4″ wood, PVC, aluminum or steel post provides a safe “break away”feature in the event that an moving vehicle comes into contact with theprefabricated column.

The columns are designed to accept various accessory devices that arefield mounted to enhance the usefulness of the column such as a mailboxkit, a light fixture kit, a light fixture mounting base kit, a plantholder bracket and illuminated house number display.

In FIG. 3, a column 39 having a mailbox 31 and a lighting kit 40 isshown. The lighting kit 40 is mounted on a top cover 44 that engageswith the top of the side walls 12, 14, 16, 18 to cover opening 20.

Turning to FIG. 4, a pillar 50 for supporting one side of a commercialsign (not shown) has an opening 53 on the side where the sign isinserted. Opening 53 extends through the core and insert of pillar 50such that a bracket (not shown) can be inserted into the opening andattached to the post at one end and attached to the surface of theoutdoor signage at the opposite end. Accordingly, the bracket and thepost are load bearing and not the pillar 50. Except for the opening 53,the core and insert are similar to the core and insert shown in FIG. 1.

The pillar 50 is slid over a 4″×4″ aluminum or steel post set inconcrete to the appropriate frost level to support the load of the sign.The bracket is bolted to the post once it is inserted into the opening53 on the side of the pillar 50. The opposite end is bolted to thefinished surface of the outdoor signage.

In FIGS. 5 and 6, alternate versions of the designs for the columns areshown. In FIG. 5, column 60 is a paneled stucco version having a topcover 44 with a light kit 40 installed therein. In FIG. 6 a brick column70 is shown with a plain top cover 80.

As shown in FIG. 7, in addition to the post hole mounting, the column ofthe present invention may be field mounted to existing concrete footers,foundations, pads, sidewalks, patios, driveways, walkways, or asphaltparking lots by using optional pad mounting brackets 90 that areattached to the bottom of a mounting post 93. The brackets 90 areattached to a concrete pad 99 by commercially available masonryfasteners or the like as will be evident to those of ordinary skill inthe art. Other shapes of brackets and mounting hole patterns including asingle bracket may also be suitable.

While the invention has been described in connection with certainembodiments, it is not intended to limit the scope of the invention tothe particular forms set forth, but, on the contrary, it is intended tocover such alternatives, modifications, and equivalents as may beincluded within the spirit and scope of the invention as defined by theappended claims.

1. A pre-fabricated outdoor column assembly, comprising: an elongatetubular member having at least one inner wall, at least one outer wall,a first end and a second end disposed opposite the first end, the atleast one outer wall having the appearance of masonry; and, an inserthaving a first end and a second end, the insert disposed inside thetubular member, the insert disposed adjacent to the at least one innerwall of the tubular member, the insert disposed in spaced apart relationto the first and second ends of the tubular member such that a firstspace between the insert and the first end of the tubular member and asecond space between the insert and the second end of the tubular memberare formed, the insert having a opening sized to receive a mounting post2. The pre-fabricated, outdoor column assembly of claim 1, wherein thetubular member further comprises an opening for receiving a mailbox intothe first space in the tubular member.
 3. The pre-fabricated, outdoorcolumn assembly of claim 1, wherein the insert further comprises araceway extending from the first end of the insert to the second end ofthe insert such that a conduit extending from the first space to thesecond space is capable of being disposed through the raceway.
 4. Thepre-fabricated, outdoor column assembly of claim 1, wherein the openingin the insert is defined by at least one first wall defining a firstopening for receiving the post and at least one second wall forming araceway disposed adjacent to the first wall such that conduit can be runinside the insert along an outside surface of the mounting post
 5. Thepre-fabricated, outdoor column assembly of claim 1, wherein the at leastone outer wall of the tubular member is coated with an elastomeric hardshell coating.
 6. The pre-fabricated, outdoor column assembly of claim5, wherein the hard shell coating comprises a polyurea based coating. 7.The pre-fabricated, outdoor column assembly of claim 6, wherein thecoating is applied by spraying.
 8. The pre-fabricated, outdoor columnassembly of claim 1, wherein the tubular member is formed byrotocasting.
 9. The pre-fabricated, outdoor column assembly of claim 1,wherein the tubular member is formed by molding.
 10. The pre-fabricated,outdoor column assembly of claim 1, further comprising a cap having alight fixture disposed therein, the cap capable of being attached to thecolumn assembly at the first end of the tubular member.
 11. Thepre-fabricated, outdoor column assembly of claim 1, wherein the mountingpost is an elongate vertical post disposed in the ground
 12. Thepre-fabricated, outdoor column assembly of claim 1, wherein the mountingpost is an elongate vertical post attached to a concrete surface. 13.The pre-fabricated, outdoor column assembly of claim 1, wherein thecolumn assembly has an elongate opening in the tubular member and has acorresponding opening in the insert such that one end of signage iscapable of being attached to the mounting post.
 14. The pre-fabricated,outdoor column assembly of claim 1, wherein the mounting post is astandard 4″×4″ post
 15. The pre-fabricated, outdoor column assembly ofclaim 1, wherein the at least one outer wall has the appearance ofbrick.
 16. The pre-fabricated, outdoor column assembly of claim 1,wherein the at least one outer wall has the appearance of paneledstucco.
 17. The pre-fabricated, outdoor column assembly of claim 1,wherein the at least one outer wall has the appearance of stone.
 18. Thepre-fabricated, outdoor column assembly of claim 1, further comprisingan illuminated house number display disposed in the column assembly. 19.The pre-fabricated, outdoor column assembly of claim 1, furthercomprising an electrical outlet disposed in the column assembly.
 20. Thepre-fabricated, outdoor column assembly of claim 1, wherein the tubularmember is formed from four walls joined at ninety degree, keyed corners.21. The pre-fabricated, outdoor column assembly of claim 1, wherein thetubular member further comprises an opening for receiving a newspaperbox.
 22. A pre-fabricated, outdoor column assembly, comprising: anelongate tubular member having at least one inner wall, at least oneouter wall, a first end, and a second end disposed opposite the firstend, the at least one outer wall having the appearance of masonry, theat least one inner wall of the tubular member defining an openingextending from the first end to the second end of the tubular member; aninsert disposed inside the tubular member in spaced apart relation tothe first and second ends of the tubular member such that a first spacebetween the insert and the first end of the tubular member and a secondspace between the insert and the second end of the tubular member areformed, the insert having a first end and a second end, the inserthaving at least one first inner wall defining an opening extending fromthe first end to the second end, the opening sized to receive a mountingpost, the insert having at least one second inner wall defining araceway such that conduit may be disposed through the insert from thefirst space to the second space; and, a cap sized to fit onto the firstend of the tubular member.
 23. The pre-fabricated, outdoor columnassembly of claim 22, wherein the tubular member further comprises anopening for receiving a mailbox into the first space in the tubularmember.
 24. The pre-fabricated, outdoor column assembly of claim 23,wherein the mailbox is attached to the top surface of the mounting post.25. The pre-fabricated, outdoor column assembly of claim 22, wherein theinsert further comprises a raceway extending from the first end of theinsert to the second end of the insert such that a conduit extendingfrom the first space to the second space is capable of being disposedthrough the raceway.
 26. The pre-fabricated, outdoor column assembly ofclaim 22, wherein the opening in the insert is defined by at least onefirst wall defining an opening for receiving the post and at least onesecond wall forming a raceway disposed adjacent to the first wall suchthat conduit can be run inside the insert along an outside surface ofthe mounting post.
 27. The pre-fabricated, outdoor column assembly ofclaim 22, wherein the at least one outer wall of the tubular member iscoated with an elastomeric hard shell coating
 28. The pre-fabricated,outdoor column assembly of claim 27, wherein the hard shell coatingcomprises a polyurea based coating.
 29. The pre-fabricated, outdoorcolumn assembly of claim 28, wherein the coating is applied by spraying30. The pre-fabricated, outdoor column assembly of claim 22, wherein thetubular member is formed by rotocasting.
 31. The pre-fabricated, outdoorcolumn assembly of claim 22, wherein the tubular member is formed bymolding.
 32. The pre-fabricated, outdoor column assembly of claim 22,further comprising a cap having a light fixture disposed therein. 33.The pre-fabricated, outdoor column assembly of claim 22, wherein themounting post is an elongate vertical post disposed in the ground. 34.The pre-fabricated, outdoor column assembly of claim 22, wherein themounting post is an elongate vertical post attached to a concretesurface.
 35. The pre-fabricated, outdoor column assembly of claim 22,wherein the column assembly has an elongate opening in the tubularmember and has a corresponding opening in the insert such that one endof signage is capable of being attached to the mounting post.
 36. Thepre-fabricated, outdoor column assembly of claim 22, wherein themounting post is a standard 4″×4″ post.
 37. The pre-fabricated, outdoorcolumn assembly of claim 22, wherein the at least one outer wall has theappearance of brick.
 38. The pre-fabricated, outdoor column assembly ofclaim 22, wherein the at least one outer wall has the appearance ofpaneled stucco.
 39. The pre-fabricated, outdoor column assembly of claim22, wherein the at least one outer wall has the appearance of stone 40.The pre-fabricated, outdoor column assembly of claim 22, furthercomprising an illuminated house number display disposed in the columnassembly.
 41. The pre-fabricated, outdoor column assembly of claim 22,further comprising an electrical outlet disposed in the column assembly.42. The pre-fabricated, outdoor column assembly of claim 22, wherein thetubular member is formed from four walls joined at ninety degree keyedcorners.
 43. The pre-fabricated, outdoor column assembly of claim 22,wherein the tubular member further comprises an opening for receiving anewspaper box.
 44. A method of constructing an outdoor column,comprising: providing an elongate tubular member having at least oneinner wall, at least one outer wall, a first end and a second enddisposed opposite the first end, the at least one outer wall having theappearance of masonry; providing an insert having a first end and asecond end and at least one inner wall defining an opening extendingfrom the first end to the second end; attaching the insert inside thetubular member adjacent to the at least one inner wall of the tubularmember, the insert disposed in spaced apart relation to the first andsecond ends of the tubular member such that a first space between theinsert and the first end of the tubular member and a second spacebetween the insert and the second end of the tubular member are formed,the tubular member and insert forming a prefabricated, outdoor column;excavating a hole in the ground; anchoring a vertical post to the hole;placing the prefabricated, outdoor column over the post such that thepost is received by the opening in the insert; and, attaching theprefabricated, outdoor column to the post.
 45. The method of claim 44,wherein the tubular member first comprises an opening for receiving amailbox into the first space in the tubular member.
 46. The method ofclaim 45, wherein the mailbox is attached to a top surface of themounting post.
 47. The method of claim 44, wherein the insert furthercomprises a raceway extending from the first end of the insert to thesecond end of the insert such that a conduit extending from the firstspace to the second space is capable of being disposed through theraceway.
 48. The method of claim 44, wherein the opening in the insertis defined by at least one first wall defining an opening for receivingthe post and at least one second wall forming a raceway disposedadjacent to the first wall such that conduit can be run inside theinsert along an outside surface of the mounting post.
 49. The method ofclaim 44, wherein the at least one outer wall of the tubular member iscoated with an elastomeric hard shell coating.
 50. The method of claim49, wherein the hard shell coating comprises a polyurea based coating.51. The method of claim 50, wherein the coating is applied by spraying.52. The method of claim 44, wherein the tubular member is formed byrotocasting.
 53. The method of claim 44, wherein the tubular member isformed by molding.
 54. The method of claim 44, further comprising a caphaving a light fixture disposed therein, the cap capable of beingattached to the first end of the tubular member.
 55. The method of claim44, wherein the mounting post is an elongate vertical post disposed inthe ground.
 56. The method of claim 44, wherein the mounting post is anelongate vertical post attached to a concrete surface.
 57. The method ofclaim 44, wherein the pre-fabricated column has an elongate opening inthe tubular member and has a corresponding opening in the insert suchthat one end of signage is capable of being attached to the mountingpost.
 58. The method of claim 44, wherein the mounting post is astandard 4″×4″ post.
 59. The method of claim 44, wherein the at leastone outer wall has the appearance of brick.
 60. The method of claim 44,wherein the at least one outer wall has the appearance of paneledstucco.
 61. The method of claim 44, wherein the at least one outer wallhas the appearance of stone.
 62. The method of claim 44, furthercomprising an illuminated house number display disposed in thepre-fabricated outdoor column assembly.
 63. The method of claim 44,further comprising an electrical outlet disposed in the pre-fabricated,outdoor column assembly.
 64. The method of claim 44, wherein the tubularmember is formed from four walls joined at ninety degree keyed corners.65. The method of claim 44, wherein the tubular member further comprisesan opening for receiving a newspaper box.
 66. A prefabricated outdoorcolumn assembly, comprising: a hollow body having an outer wall, a topsurface and a bottom surface, the outer wall having the appearance ofmasonry, the body having a first cavity disposed between the bottom andtop surfaces, the first cavity having an opening associated with thebottom surface and sized to receive a mounting post, the body having asecond cavity larger than the first cavity and disposed between thefirst cavity and the top surface, the body having a passageway in opencommunication between the outer wall mid the second cavity, thepassageway capable of receiving a structure.